Development and characterization of a novel AA6061 composite reinforced with titanium aluminide via friction stir processing

Current research work emphasizes on the development of particulate titanium aluminide (TiAl), an intermetallic class of material, through mechanical alloying (MA) from elemental powders and usage of same as reinforcement in AA6061 aluminum matrix to enhance its mechanical and tribological performance. TiAl, being a light weight, strong and abrasion-resistant material, is found to be a suitable candidate to replace dense ceramic-based reinforcements in aluminum composite. Friction stir processing (FSP), a well-established surface severe plastic deformation tool, is used to develop the composite in this study. Several strategies on improving the stirring action and particle distribution during FSP is employed and their scientific effect is studied in detail. Microstructural evolution was studied through scanning electron microscopy (SEM) combined with electron backscattered diffraction (EBSD) analysis which revealed uniform particle distribution of reinforcement in the friction stir processed (FSPed) zone with 88.23 % reduction in grain size of composite as compared to base material. Hardness studied showed an increase in the hardness by 33 % for composite material as compared to un-reinforced FSPed material, showing the positive effect of reinforcement alone on the mechanical strength of the material. Tensile results showed an improvement in yield tensile strength from 156 MPa in base to 186.8 MPa in the composite material without significant compromise in the ductility 26.86 % for composite and 28.14 % for base. Mechanisms aiding uniform particle distribution, and the reasons for improvement in mechanical performance of the developed composite is discussed in detail with the help of microstructural studies and post-deformation fractograph.